Patent application title: FRAME MOUNTED MODULAR HYBRID COOLING SYSTEM

Abstract:

A modular cooling system (10) for a vehicle is provided. The modular
cooling system (10) includes a frame (12) adapted to be mounted to a
portion of a vehicle. A heat-generating component (16) and a plurality of
cooling components (18, 22, 24, 26) are received on the frame (12). At
least one of the cooling components (18, 22, 24, 26) is placed into
communication with the heat-generating component (16).

Claims:

1. A modular cooling system for a vehicle, comprising:(a) a frame adapted
to be mounted to a portion of a vehicle;(b) a heat-generating component
received on the frame; and(b) a plurality of cooling components received
on the frame, wherein at least one of the cooling components is placed
into fluid communication with the heat-generating component.

2. The modular cooling system of claim 1, wherein at least one of the
cooling components and the heat-generating component are placed into
fluid communication with coolant lines.

3. The modular cooling system of claim 1, further comprising coolant added
to at least one of the cooling components.

4. The modular cooling system of claim 1, wherein the cooling components
include a coolant pump, a cooling fan, and a heat exchanger.

5. The modular cooling system of claim 1, wherein the heat-generating
component is an inverter.

6. The modular cooling system of claim 1, further comprising a plurality
of heat-generating components secured to the frame.

7. The modular cooling system of claim 1, further comprising a vehicle
component secured to the frame.

8. The modular cooling system of claim 1, wherein the frame is mountable
to a side rail of the vehicle.

9. A method for providing a cooling system for cooling a heat-generating
component of a vehicle, the method comprising:(a) securing a
heat-generating component on a frame;(b) securing a plurality of cooling
components on the frame;(c) placing at least one of the cooling
components into fluid communication with the heat-generating component;
and(d) mounting the frame to the vehicle.

10. The method of claim 9, wherein at least one of the cooling components
and the heat-generating component are placed into fluid communication
with coolant lines.

11. The method of claim 9, further comprising adding coolant to at least
one of the cooling components prior to mounting the frame to the vehicle.

12. The method of claim 9, further comprising placing at least one of the
cooling components and the heat-generating component into electrical
communication with a power source.

13. The method of claim 9, wherein the cooling components include a
coolant pump, a cooling fan, and a heat exchanger.

14. The method of claim 9, wherein the heat-generating component is an
inverter.

15. The method of claim 9, further comprising securing a plurality of
heat-generating components to the frame and thereafter placing the
heat-generating components into fluid communication with at least one of
the cooling components.

16. The method of claim 9, further comprising mounting a vehicle component
to the frame.

17. The method of claim 9, wherein the mounting step comprises mounting
the frame to a side rail of the vehicle.

Description:

BACKGROUND

[0001]Hybrid drive vehicles, which use both electrical and internal
combustion engine power, include certain power electronic devices that
convert, manage, and distribute power and energy in hybrid vehicle
applications. These devices, such as semiconductors,
converters/inverters, battery packs, controllers, and switches, are
important to developing an efficient and high-performance hybrid vehicle
system. For instance, in heavy hybrid vehicles, converters and inverters
condition and control the electrical signal between the energy storage
unit (such as the battery pack) and the motor/generator to provide power
to various components at critical times.

[0002]Hybrid drive vehicles need proper thermal management of the hybrid
components for optimum performance and durability. Therefore, hybrid
vehicles typically require supplemental cooling loops, separate from the
primary engine, to maintain a proper operating temperature for the
heat-generating components of the hybrid drive system. Typically, the
components of a cooling system are individually mounted to the vehicle in
a suitable location for cooling the desired component. The cooling
components are thereafter placed into fluid communication with a coolant
loop or coolant lines and heat-generating components. The necessary
electrical systems must also be installed for controlling the cooling
components.

[0003]Separately installing each cooling component and associated
electrical control system increases installation time and cost. Moreover,
planning the location for each cooling component relative to the
heat-generating components can take significant amounts of time,
especially when installing the components on various vehicle models.
These installation and design costs contribute to the overall cost of
manufacturing the vehicle, thus increasing the cost to the purchaser or
reducing the profit of the manufacturer. It is desired to have a cooling
system that can be used to cool a variety of heat-generating components
and mounted to a variety of different vehicles in a simplified manner to
reduce installation time and costs.

SUMMARY

[0004]A modular cooling system for a vehicle is provided. The modular
cooling system includes a frame adapted to be mounted to a portion of a
vehicle. A heat-generating component and a plurality of cooling
components are received on the frame. At least one of the cooling
components is placed into fluid communication with the heat-generating
component.

[0005]A method for providing a cooling system for cooling a
heat-generating component of a vehicle is also provided. The method
includes securing a heat-generating component on a frame, securing a
plurality of cooling components on the frame, placing at least one of the
cooling components into fluid communication with the heat-generating
component, and mounting the frame to the vehicle.

[0006]By installing and plumbing the cooling components and the
heat-generating component prior to mounting the frame to the vehicle,
vehicle assembly costs are minimized. Rather than securing each component
individually to the vehicle and thereafter placing the component into
communication with the other components, the components are mounted to
the vehicle in one step. Moreover, packaging the cooling system together
with the heat-generating component allows the cooling system to be
mounted in a variety of locations on the vehicle and on a variety of
different vehicles.

[0007]This summary is provided to introduce a selection of concepts in a
simplified form that are further described below in the Detailed
Description. This summary is not intended to identify key features of the
claimed subject matter, nor is it intended to be used as an aid in
determining the scope of the claimed subject matter.

DESCRIPTION OF THE DRAWINGS

[0008]The foregoing aspects and many of the attendant advantages of this
invention will become more readily appreciated as the same become better
understood by reference to the following detailed description, when taken
in conjunction with the accompanying drawings, wherein:

[0009]FIG. 1 is an environmental view of a representative embodiment of a
modular cooling system mounted to a truck constructed in accordance with
one embodiment of the present disclosure;

[0010]FIG. 2 is an environmental view of the modular cooling system of
FIG. 1 mounted to the frame rail of a truck;

[0011]FIG. 3 is an isometric view of the modular cooling system of FIG. 1;
and

[0012]FIG. 4 is an exploded view of the modular cooling system of FIG. 1.

DETAILED DESCRIPTION

[0013]A modular cooling system 10 constructed in accordance with one
embodiment of the present disclosure is best seen by referring to FIGS. 1
and 2. The modular cooling system 10 is shown secured to a portion of a
truck A; however, it should be appreciated that placement of the modular
cooling system 10 is not so limited, with other mounting locations being
within the scope of the present disclosure. From time to time throughout
this specification, directional terms, such as vertical, horizontal, top,
bottom, etc., are used in the description of various components. It
should be apparent that the use of such terms is merely for convenience
and, as such, is not intended to limit the embodiments or claims
contained herein. The modular cooling system 10 may be mounted to any
suitable portion of the truck A. In the embodiment of FIG. 1, the modular
cooling system 10 is secured to a frame rail B of the truck A behind the
cab D and in front of the fuel tank C.

[0014]Referring to FIG. 3, the illustrated modular cooling system 10
includes a plurality of cooling components that cool at least one
heat-generating vehicle component. The heat-generating component is
integrated within the modular cooling system 10 such that it may be
placed into fluid communication with the plurality of cooling components.
FIG. 3 depicts the heat-generating component as an inverter 16 for a
hybrid vehicle. Other components may be cooled in addition to or instead
of the inverter 16. For instance, the modular cooling system 10 may
include heat-generating components in the form of a down converter, a
battery pack, a semiconductor, a controller, a switch, etc.

[0015]The cooling components of the modular cooling system 10 are packaged
together on a suitable frame 12. The cooling components include, but are
not limited to, a coolant pump 18 (with an optional integrated
controller), a cooling fan 22, a heat exchanger 24, and a fan controller
26. The cooling components may be any suitable off-the-shelf components
that are adapted to cooperate and sufficiently cool the heat-generating
component(s), such as the inverter 16. Other cooling components may be
included in the modular cooling system 10 in addition to or instead of
the cooling components listed above. For instance, the system may include
a cooling reservoir or additional fans or heat exchangers.

[0016]Referring to FIGS. 2 and 3, the frame 12 may be of a size and shape
designed to receive the heat-generating component and the cooling
components. The illustrated frame 12 has an inverted U-shape in
cross-section such that it includes a horizontal portion 28 and two
vertical side portions 30 extending downwardly therefrom. The frame 12
may include a plurality of openings formed in the horizontal portion 28
and the vertical side portions 30 such that components may be easily
mounted beneath or inside the frame 12 and air may flow throughout the
modular cooling system 10. A pair of mounting brackets 34 are secured to
the forward portion of the frame 12 for mounting the frame 12 to the
vehicle frame rail B. The mounting brackets 34 may be any suitable shape
and size. An exemplary bracket 34 is preferably L-shaped in cross-section
and includes a side portion 36 and a forward portion 38. A plurality of
fasteners (not shown) pass through the side portion 36 and the vertical
side portion 30 to couple the mounting bracket 34 to the frame 12. The
forward portion 38 is adapted to receive a plurality of fasteners to
couple the forward portion 38 to the frame rail B, thereby securing the
frame 12 to the frame rail B. It should be appreciated that the frame 12
may instead be mounted to the frame rail B or another portion of the
truck A in any other well-known manner.

[0017]In the alternative, the frame 12 may be a suitable platform device
that is adapted to receive the heat-generating component and the cooling
components thereon. The platform device may be formed from a sheet of
material, such as metal, that is either bent at the edges or includes
mounting brackets secured thereto for mounting the platform horizontally
to the frame rail B. A plurality of fasteners may be used to secure the
components to the platform.

[0018]A separate bracket may be secured to the frame 12 for mounting any
of the various components to the frame 12. For instance, a pump bracket
32 is used to mount the coolant pump 18 to the frame 12. The pump bracket
32 is adapted to receive the coolant pump 18 and secure it to the frame
12 such that the pump 18 may be placed into communication with the other
components. Preferably, the pump bracket 32 includes a flange 33 that is
mounted to the forward portion 38 of either mounting bracket 34.

[0019]The cooling fan 22 may be secured to the frame 12 with a fan bracket
40. The fan bracket 40 includes a fan-receiving portion 41 for receiving
the cooling fan 22 therewithin and side flanges 42 formed on each side of
the fan-receiving portion 41. The side flanges 42 are mateable with the
vertical side portions 30 of the frame 12. The fan controller 26 is
mounted in any suitable manner to the interior surface of the frame 12
such that it may be placed into electrical communication with the fan 22.
The heat exchanger 24 is mounted to the bottom of the fan bracket 40 with
a plurality of fasteners, and a grill 44 is secured to the frame 12 to
substantially enclose the fan 22 and heat exchanger 24 within the frame
12.

[0020]The inverter 16 is suitably mounted to the horizontal portion 28 of
the frame 12 such that it may be placed into communication with the
cooling components. The inverter 16 is coupled to the exterior surface of
the horizontal portion 28 of the frame 12. In this manner, the inverter
16 is accessible such that it may be easily placed into electrical
communication with other vehicle components. It should be appreciated
that the inverter 16 may instead be mounted to any portion of the frame
12. Moreover, other heat-generating components may also be suitably
mounted to the frame 12.

[0021]The frame 12, brackets 32, 34, and 40, and grill 44 are made from
any suitable material, such as sheet metal. It should be appreciated that
frame 12, brackets 32, 34, and 40, and grill 44 may be formed in any
suitable shape and size such that the cooling components and the
heat-generating components are mountable within the frame 12 to package
all the components into a modular cooling system 10.

[0022]The frame 12 may be mounted to the vehicle A such that it provides
structural support for the vehicle or other vehicle components. For
instance, the frame 12 may include a pair of steps (not shown) mounted to
its exterior such that when the system 10 is mounted beneath the truck
cab B, a user could climb the steps to access upper portions of the cab
exterior. The frame 12 may also include mounting features for securing
other vehicle components to the frame 12. In this manner, the frame rail
B could be reserved for other components, such as larger fuel tanks.

[0023]To use the modular cooling system 10, the cooling components and
heat-generating components are mounted to the frame 12 in the manner
described above. The coolant pump 18, heat exchanger 24, and inverter 16
are placed into fluid communication with coolant lines (not shown) to
define a coolant loop within the modular cooling system 10. A suitable
coolant is thereafter added to the coolant loop in a manner well known in
the art. The components are also wired together as necessary in a manner
well-known in the art.

[0024]After securing the components to the frame 12 and placing the
components into fluid and/or electrical communication with each other,
the frame 12 is mounted to the frame rail B by securing the mounting
brackets 34 to the frame rail B. The electrical components are thereafter
placed into electrical communication with a power source on the vehicle
(not shown). It should be appreciated that the electrical components may
instead be placed into electrical communication with a power source on
the frame 12 before the frame 12 is mounted to the vehicle. If needed,
the cooling components may also be placed into fluid communication with
other heat-generating components on the vehicle A.

[0025]Packaging the components together as a single modular cooling system
10 allows an operator to mount the cooling components and the
heat-generating component to the vehicle in a single installation. Having
the ability to mount the components to the vehicle at one time in a
single installation, as well as being able to wire and plumb the
components prior to installation, reduces manufacturing time and costs.

[0026]While illustrative embodiments have been illustrated and described,
it will be appreciated that various changes can be made therein without
departing from the spirit and scope of the invention.